Stackable modular personal computer array

ABSTRACT

One aspect of this disclosure is directed to a sub-rack module for supporting a personal computer chassis therein. The sub-rack module is configured to be received within a multi-position support rack. Due to the unique combination of the sub-rack and the multi-position support rack, the sub-rack modules can be positioned such that the back ends of the personal computer chassis form an air passageway in the center of the multi-position support rack, which allows for the air flow to be directed through the passageway and out through the front end of the personal computer chassis. This configuration allows for the high density storage of an array of personal computer chassis while providing adequate cooling for multiple units. A method for manufacturing this system is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.12/770,934, filed Apr. 30, 2010, pending, the disclosures of which arefully incorporated herein by reference for all purposes.

TECHNICAL FIELD

This application is directed, in general, to a network of personalcomputers and, more specifically, to a modular, centralized, highdensity, personal computer system with remote operation.

BACKGROUND

Presently, most office environments are served by a computer systemcomprising a central server coupled to a local area network (LAN) andoften also to a wide area network (WAN) and the Internet. Coupled to theLAN is a plurality of personal computers distributed throughoutindividual offices of the company. This provides a central locationwhere the server and the networks can easily be maintained by aninformation technology (IT) technician. With the personal computersdistributed in individual offices, data that may be required by morethan one user must be copied or transferred to the central server orsoftware network provisions made for, usually secure, access to acomputer in another part of the company. For example, a largeheadquarters building of a company, e.g. a bank, may have workers overseveral floors that need to access individual account data at varyingtimes, e.g., teller, home loan department, vehicle loan department,etc., Additionally, with personal computers distributed throughoutspaced-apart offices, the cooling requirements are more distributed,perhaps frequently requiring re-balancing the office air conditioningsystems as seasons change. Moreover, individual computer units arerelatively large and take up space within the individual's office.

SUMMARY

One aspect, as set forth herein, provides a sub-rack module forsupporting a personal computer chassis therein. In this aspect, thesub-rack module comprises an open-ended support module having a top, abottom, and first and second sides, and a through aperture extendingfrom a front of the open-ended support module to a rear of saidopen-ended support module. The through aperture has a side-to-side widthsufficient to receive a computer chassis therein. The top side of theopen-ended support module has a front to rear length such thatventilation apertures of the computer chassis are exposed at the rearwhen the computer chassis is positioned within the open-ended supportmodule.

In another aspect a system for stacking modular personal computers isprovided. This embodiment comprises open-ended support modules eachhaving a top, a bottom, and first and second sides, and a throughaperture extending from a front to a rear of the open-ended supportmodules. The through apertures have a side-to-side width sufficient toreceive at least one computer chassis therein. The top side of eachopen-ended support module has a front to rear length such thatventilation apertures of a computer chassis are exposed at the rear whenthe at least one computer chassis is positioned within the open-endedsupport module. This embodiment further includes a multi-positionsupport rack having frame support members coupled together to form aplurality of support locations for the open-ended support modules. Theopen-ended support modules are located within and supported by themulti-position support rack at least a portion of the support locations.

In a further aspect, a method of manufacturing a system for stackingmodular personal computers is provided. This embodiment comprisesforming a plurality of open-ended support modules, each having a top, abottom, and first and second sides, and a through aperture extendingfrom a front of the open-ended support module to a rear of theopen-ended support module. The through aperture has a side-to-side widthsufficient to receive at least one computer chassis therein. The topside of the open-ended support module has a front to rear length suchthat ventilation apertures of the computer chassis are exposed at therear of the open-ended support module when the computer chassis ispositioned within the open-ended support module. The method furtherincludes forming a multi-position support rack having frame supportmembers coupled together to form a plurality of support locations forthe open-ended support modules, and removably securing at least aportion of the open-ended support modules within the multi-positionsupport rack at one of the support locations.

BRIEF DESCRIPTION

Reference is now made to the following descriptions taken in conjunctionwith the accompanying drawings, in which:

FIG. 1A is an isometric view of one embodiment of an open-ended supportmodule constructed according to the principles of the present invention;

FIG. 1B is an isometric view of one embodiment of a computer chassisconstructed according to the principles of the present invention;

FIG. 2 is an isometric view of the open-ended support module with twopersonal computer chassis inserted therein; and

FIG. 3 is an isometric view of 12 open-ended support modules with twopersonal computer chassis inserted in each open-ended support module ofa multi-position support rack.

DETAILED DESCRIPTION

Referring initially to FIG. 1A, illustrated is an isometric view of oneembodiment of a sub-rack module 100 constructed according to theprinciples of the present invention. The sub-rack module 100 comprisesan open-ended support module 100 having a top 101, a bottom 102, firstand second sides 103, 104, respectively, an optional central divider orpartition 107, first and second mounting flanges 108, 109, respectively,and a through aperture 114. The through aperture 114 extends from afront 111 of the open-ended support module 100 to a rear 112 of theopen-ended support module 100. In one embodiment, the through aperture114 has a side-to-side width sufficient to receive at least one computerchassis therein. However, in other embodiments, the through aperture's114 width is sufficient to provide for two or more computer chassis 120.In one aspect, the through aperture 114 is partitioned into first andsecond computer chassis sub-bays 105, 106, respectively. The partition107 may be a panel or a bracket, as shown, and may serve as additionalsupport structure for the open-ended support module 100. The mountingflanges 108, 109 may be configured as shown with which bolts and nutscan be used to removably secure the open-ended support module 100 to asupport frame. However, in other embodiments, the mounting flanges 108,109 may include other means such as friction clamps that can be used toremovably secure the open-ended support module 100 to a support frame.

In an alternative embodiment, the open-ended support module 100 mayfurther include notches 113 in the first and second sides 103, 104,respectively, adjacent the rear of the open-end support module 100. Asmentioned below, the notches 113 can serve as an opening to facilitateair flow into the back end of the computer chassis 120. When present incertain embodiments, the first and second mounting flanges 108, 109,respectively, extend laterally from the front end 111 on opposing sidesof the open-ended support module 100. The open-ended support module 100may be constructed of any suitable rigid sheet-like material such assheet metal or hard plastic that is sufficiently strong to support theweight of the open-ended support module 100 or modules.

Referring now to FIG. 1B, illustrated is an isometric view of oneembodiment of a computer chassis 120 constructed according to theprinciples of the present invention. Though the computer chassis 120 isnot limited to any particular size, it is particularly advantageous thatthe computer chassis 120 is compact in size and significantly smallerthat typical desk top models; that is the length may typically varybetween about 12, 16, and 18 inches, while the overall width may varybetween about 6 to 8 inches, and the thickness may be about 3 to 4inches. The compact size of the computer chassis 120 is particularlyadvantageous in that the units can be centralized in one location, asopposed to computer chassis being located at multiple stations. Thecentralization provides greater control over the individual computerchassis, and given that they can be centralized in one location,security can be much improved. However, such centralization and theracking of multiple heat generating computer chassis gives rise toserious cooling considerations, which is what the present disclosureaddresses.

In one embodiment, the computer chassis 120 comprises main and secondarycooling fans 121, 122, respectively; and top, side and front ventilationapertures, 123, 124, 125, respectively, and an optional swingable handle126. The cooling fans 121, 122 and the ventilation apertures 123, 124,and 125 allow for an air flow in a direction that is from the back tothe front of the computer chassis 120, and indicated by the large arrowsshown in FIG. 1B. In this particular embodiment and when used inconjunction with the open-ended support module 100, this air flow allowsfor efficient cooling when multiple computer chassis 100 are rackedtogether in one central location.

The main and secondary cooling fans 121, 122, respectively, are internalto the computer chassis 120. For clarity, the other components of thepersonal computer within the computer chassis 120, e.g., hard drive,motherboard, microprocessor, etc., are not shown and may be ofconventional design. Ambient cooling air is drawn in through the top andside ventilation apertures 123, 124 by the main cooling fan 121. Theair, having been heated by the electronics of the personal computer, isexpelled through the front ventilation apertures 125 with the assistanceof the secondary cooling fan 122. The optional swingable handle 126 isrotatably coupled to the upper front corners of the computer chassis 120and may be used to carry, remove, and insert the computer chassis 120into the first or second through apertures 105, 106, respectively. Themouse and keyboard connect to the computer chassis 120 over Ethernet.The end user can plug in any USB device at the client side and thesignal is carried to the computer chassis 120 over Ethernet. Thecomputer within the computer chassis 120 decodes the signal fromEthernet to USB and sees the mouse and keyboard. Power, Ethernet andPCoIP signal as made through the front panel of the computer chassis120.

Referring now to FIG. 2, illustrated is an isometric view of theopen-ended support module 100 with two personal computer chassis 120inserted therein. In this illustrated embodiment, the first and secondcomputer chassis sub-bays 105, 106 are configured to each receive thepersonal computer chassis 120 therein, and the open-ended support module100 has a front 111 to rear 112 length 127 such that the top ventilationapertures 123 adjacent the back end of the computer chassis 120 extendbeyond the rear 112 of the open-ended support module 100. Thiscooperative configuration is particularly advantageous in that the airflow from the back to the front of the computer chassis 120 is notblocked or inhibited by any portion of the open-ended support module100. Optional notches 113 in the first and second sides 102, 103,respectively, permit additional cooling air to enter through the sideventilation apertures 124 when the personal computer chassis 120 isfully inserted into the first and second computer chassis sub-bays 105,106.

Referring now to FIG. 3, illustrated is one embodiment of an isometricview of 12 open-ended support modules 100 with two personal computerchassis 120 inserted in each open-ended support module 100 of amulti-position support rack 300. The multi-position support rack 300comprises a plurality of frame support members 305 coupled together toform a plurality of support locations for the open-ended support modules100. The mounting flanges 108, 109 are configured to cooperate with theframe support members 305 to removably fasten the open-ended supportmodules 100 at the desired support locations. The top and sides havebeen removed from the multi-position support rack 300 for better viewingof the contents.

The two stacks of six open-ended support modules 100 with 12 personalcomputer chassis 120 each are located on opposing sides of themulti-position support rack 300 and are advantageously arranged suchthat the back ends of the computer chassis 120 oppose each other. Thisunique configuration forms an air passageway 310 between the rears ofthe two stacks of personal computer chassis 120 and forms an open airconduit for air to flow from the air passageway 310, through thecomputer chassis 120 and out the opposing sides of the multi-positionsupport rack 300. More specifically, air flows into the top and optionalside ventilation apertures 123, 124, respectively, of each of thepersonal computer chassis 120 and out the front ventilation apertures125. This unique configuration allows for efficient cooling ofmulti-heat generating personal computers, while allowing them to beracked in a single centralized location.

While a multi-position support rack 300 with 24 personal computers isillustrated, one who is of skill in the art will recognize that themulti-position support rack 300 may comprise any number of open-endedsupport modules 100 arranged so as to position the computer chassis 120mounted therein with the rear ends of the chassis opposing.

Thus, a stackable modular personal computer array has been describedthat concentrates the computer hardware in one large, multi-positionsupport rack. Therefore, air conditioning can be provided to accommodatethe heat output of the stackable modular personal computer array. Withall of the computers commonly located, information can be accessed byany authorized used remotely from the computer array anywhere in thecompany as well as the information technology technician does not needto walk back and forth from the server room to the office with acomputer problem. Furthermore, connecting a keyboard, mouse, etc., canbe readily accomplished to a problem computer and diagnosis made. Ifnecessary, the problem computer can be removed from the open-endedsupport module and replaced with a known good computer.

Those skilled in the art to which this application relates willappreciate that other and further additions, deletions, substitutionsand modifications may be made to the described embodiments, for instancethe following example claims from U.S. Application Ser. No. 12/770,934,filed on Apr. 30, 2010 which have been incorporated herein:

1. A sub-rack module for supporting a personal computer chassis therein,comprising: an open-ended support module having a top, a bottom, andfirst and second sides, and a through aperture extending from a front ofsaid open-ended support module to a rear of said open-ended supportmodule, said through aperture having a side-to-side width sufficient toreceive a computer chassis therein, said top of said open-ended supportmodule having a front to rear length such that ventilation apertures ofsaid computer chassis are exposed at said rear when said computerchassis is positioned within said open-ended support module.

2. The sub-rack module recited in claim 1 wherein said through aperturehas a width configured to receive at least two computer chassis therein.

3. The sub-rack module recited in claim 2 wherein said through apertureis partitioned into at least two computer chassis sub-bays and each ofsaid sub-bays has a width configured to receive a computer chassistherein.

4. The sub-rack module recited in claim 1 further comprising opposingmounting flanges laterally extending from a front end of said open-endedsupport module, wherein said mounting flanges are configured to enablesaid open-ended support module to be removably fastened to a supportingframe.

5. The sub-rack module recited in claim 1, wherein said first and secondsides of said open-ended support module include notches adjacent saidrear formed therein such that side ventilation apertures of a computerchassis are exposed through said notches when said computer chassis ispositioned within said open-ended support module to allow air flowthrough said notches and into said computer chassis.

6. A system for stacking modular personal computers, comprising:open-ended support modules each having a top, a bottom, and first andsecond sides, and a through aperture extending from a front to a rear ofeach of said open-ended support modules, said through apertures having aside-to-side width sufficient to receive at least one computer chassistherein, said top having a front to rear length such that ventilationapertures of a computer chassis are exposed at said rear when saidcomputer chassis is positioned within said open-ended support module;and a multi-position support rack having frame support members coupledtogether to form a plurality of support locations for said open-endedsupport modules, and wherein said open-ended support modules are locatedwithin and supported by said multi-position support rack at least aportion of said support locations.

7. The system recited in claim 6 further including at least one computerchassis received in at least a portion of said open-ended supportmodules, said at least one computer chassis having top ventilationapertures located on a top side adjacent a back end thereof, sideventilation apertures located on first and second sides adjacent saidback end thereof, and front ventilation apertures located on a frontside of said computer chassis.

8. The system recited in claim 7 wherein said frame support members havesupport locations on opposing sides of said multi-position support rackand wherein said open-ended support modules are positioned verticallyand horizontally with respect to each other within said multi-positionsupport rack and are removably secured to said multi-position supportrack at said support locations such that said top ventilation aperturesof said computer chassis are opposing each other and spaced apart toform an air passageway between opposing back ends of said computerchassis, said computer chassis having at least one fan located thereinthat directs air through said top ventilation apertures at said back endof said computer chassis and toward and through said front ventilationapertures, such that air is circulated from said passageway and througheach of said computer chassis and outward through said front ventilationapertures.

9. The system recited in claim 7 wherein said first and second sides ofsaid open-ended support modules include notches formed therein adjacentsaid rear such that said side ventilation apertures are exposed throughsaid notches when said at least one computer chassis is positionedwithin said open-ended support module to allow air flow through saidnotches and into said computer chassis through said side ventilationapertures.

10. The system recited in claim 7, wherein said computer chassis furtherincludes a rotatable handle attached in said front side of said computerchassis.

11. The system recited in claim 6 wherein each of said open-endedsupport modules further comprise opposing mounting flanges laterallyextending from said front of each of said open-ended support modules,wherein said mounting flanges and said frame support members areconfigured to enable said open-ended support modules to be removablyfastened to said frame support members at said support locations of saidmulti-position support rack.

12. A method of manufacturing a system for stacking modular personalcomputers, comprising: forming a plurality of open-ended supportmodules, each having a top, a bottom, and first and second sides, and athrough aperture extending from a front of said open-ended supportmodule to a rear of said open-ended support module, said throughaperture having a side-to-side width sufficient to receive at least onecomputer chassis therein, said top side of said open-ended supportmodule having a front to rear length such that ventilation apertures ofsaid computer chassis are exposed at said rear of said open-endedsupport module when said computer chassis is positioned within saidopen-ended support module; forming a multi-position support rack havingframe support members coupled together to form a plurality of supportlocations for said open-ended support modules; and removably securing atleast a portion of said open-ended support modules within saidmulti-position support rack at one of said support locations.

13. The method recited in claim 12 further comprising placing at leastone computer chassis in at least one of said open-ended support modulessuch that top ventilation apertures located on a top side and adjacent aback end of said computer chassis extend beyond said top side of saidopen-ended support module.

14. The method recited in claim 13 wherein removably securing one ofsaid open-ended support modules further comprises removably securingsaid open-ended support modules within said frame support at supportlocations on opposing sides of said multi-position support rack andwherein said open-ended support modules are positioned vertically andhorizontally with respect to each other within said multi-positionsupport rack such that said top ventilation apertures of said computerchassis are opposing each other and spaced apart to form an airpassageway between said rear ends of said computer chassis.

15. The method recited in claim 13 wherein forming a plurality ofopen-ended support modules includes forming open-ended support moduleshaving first and second sides that include notches formed thereinadjacent said rear such that side ventilation apertures of said computerchassis are exposed through said notches when said computer chassis ispositioned within said open-ended support module to allow air flowthrough said notches and into said computer chassis through said sideventilation apertures.

16. The method recited in claim 12, wherein forming a plurality ofopen-ended support modules further comprises forming opposing mountingflanges laterally extending from a front end of said open-ended supportmodule, wherein said mounting flanges are configured to enable saidopen-ended support modules to be fastened to a supporting frame, andremovably securing includes securing said open-ended support modules tosaid frame support members via said mounting flanges.

17. The method recited in claim 12 wherein forming a plurality ofopen-ended support modules comprises forming said through aperture witha width configured to receive at least two computer chassis therein.

18. The method recited in claim 17 wherein forming a plurality ofopen-ended support modules comprises partitioning said through apertureinto at least two computer chassis sub-bays and each of said sub-bayshas a width configured to receive a computer chassis therein.

What is claimed:
 1. A storage system comprising: a first plurality ofcomputer housings; a second plurality of computer housings; a thirdplurality of computer housings; a fourth plurality of computer housings;a storage unit, including: a first plurality of sleeves sized toslidingly accommodate the first plurality of computer housings whereineach sleeve in the first plurality of sleeves is positioned verticallywith respect to its adjacent sleeve in the first plurality of sleeves toform a first stack of sleeves, a second plurality of sleeves sized toslidingly accommodate the second plurality of computer housings whereineach sleeve in the second plurality of sleeves is positioned verticallywith respect to its adjacent sleeve in the second plurality of sleevesto form a second stack of sleeves, a third plurality of sleeves sized toslidingly accommodate the third plurality of computer housings whereineach sleeve in the third plurality of sleeves is positioned verticallywith respect to its adjacent sleeve in the third plurality of sleeves toform a third stack of sleeves, a fourth plurality of sleeves sized toslidingly accommodate the fourth plurality of computer housings whereineach sleeve in the fourth plurality of sleeves is positioned verticallywith respect to its adjacent sleeve in the fourth plurality of sleevesto form a fourth stack of sleeve, wherein the first stack of sleeves ispositioned adjacent to the second stack of sleeves to form a first rowof stacks having a front side and a back side, wherein the third stackof sleeves is positioned adjacent to the fourth stack of sleeves to forma second row of stacks having a front side and a back side, wherein thefirst row of stacks is positioned adjacent to the second row of stackssuch that the back side of the first row of stacks and the back side ofthe second row of stacks face each other and form an unobstructed spaceto create an air vertical flow path, wherein each computer housing ofthe first, second, third, and fourth pluralities of computer housingsfurther comprises: a first plurality of inlet air flow holes defined ona side wall of each housing, and a second plurality of inlet air flowholes defined on a top wall of each housing such that the secondplurality of inlet air flow holes are exposed beyond a rear of therespective sleeve of the first, second, third, and fourth plurality ofsleeves, and a first plurality of outlet air flow holes defined on afront wall of each housing, wherein each computer housing of the first,second, third, and fourth pluralities of computer housings furthercomprises a plurality of apertures defined on the front wall of eachcomputer housing sized to allow the passage of network and power cords,and wherein each computer housing of the first, second, third, andfourth pluralities of computer housings is coupled to a rotatable handleand a fastening mechanism to secure each computer housing to a supportframe.
 2. A storage system comprising: a first plurality of computerhousings; a second plurality of computer housings; a third plurality ofcomputer housings; a fourth plurality of computer housings; a storageunit, including: a first plurality of sleeves sized to slidinglyaccommodate the first plurality of computer housings wherein each sleevein the first plurality of sleeves is positioned vertically with respectto its adjacent sleeve in the first plurality of sleeves to form a firststack of sleeves, a second plurality of sleeves sized to slidinglyaccommodate the second plurality of computer housings wherein eachsleeve in the second plurality of sleeves is positioned vertically withrespect to its adjacent sleeve in the second plurality of sleeves toform a second stack of sleeves, a third plurality of sleeves sized toslidingly accommodate the third plurality of computer housings whereineach sleeve in the third plurality of sleeves is positioned verticallywith respect to its adjacent sleeve in the third plurality of sleeves toform a third stack of sleeves, a fourth plurality of sleeves sized toslidingly accommodate the fourth plurality of computer housings whereineach sleeve in the fourth plurality of sleeves is positioned verticallywith respect to its adjacent sleeve in the fourth plurality of sleevesto form a fourth stack of sleeve, wherein the first stack of sleeves ispositioned adjacent to the second stack of sleeves to form a first rowof stacks having a front side and a back side, wherein the third stackof sleeves is positioned adjacent to the fourth stack of sleeves to forma second row of stacks having a front side and a back side, wherein thefirst row of stacks is positioned adjacent to the second row of stackssuch that the back side of the first row of stacks and the back side ofthe second row of stacks face each other and form an unobstructed airflow path, and wherein each computer housing of the first, second,third, and fourth pluralities of computer housings further comprises: afirst plurality of inlet air flow holes defined on a side wall of eachhousing, and a second plurality of inlet air flow holes defined on a topwall of each housing such that the second plurality of inlet air flowholes are exposed beyond a rear of the respective sleeve of the first,second, third, and fourth plurality of sleeves, a first plurality ofoutlet air flow holes defined on a front wall of each housing; andwherein each computer housing of the first, second, third, and fourthpluralities of computer housings further comprises a plurality ofapertures defined on a front wall of each computer housing sized toallow the passage of network and power cords.
 3. The storage system ofclaim 2, wherein each computer housing of the first, second, third, andfourth pluralities of computer housings is coupled to a rotatablehandle.
 4. The storage system of claim 2, wherein each computer housingof the first, second, third, and fourth pluralities of computer housingsis coupled to fastening mechanism to releasibly secure each computerhousing to a support frame.
 5. A method of cooling a plurality ofcomputers, where each computer has a housing, the method comprising:positioning a first plurality of computers into a first plurality ofsleeves, wherein each sleeve in the first plurality of computers issized to slidingly accommodate at least one of the first plurality ofcomputers wherein each sleeve in the first plurality of sleeves ispositioned vertically with respect to its adjacent sleeve in the firstplurality of sleeves to form a first stack of sleeves, positioning asecond plurality of computers into a second plurality of sleeves,wherein each sleeve in the second plurality of sleeves is sized toslidingly accommodate at least one of the second plurality of computerswherein each sleeve in the second plurality of sleeves is positionedvertically with respect to its adjacent sleeve in the second pluralityof sleeves to form a second stack of sleeves, positioning a thirdplurality of computers into a third plurality of sleeves, wherein eachsleeve in the third plurality of sleeves sized to slidingly accommodateat least one of the third plurality of computers wherein each sleeve inthe third plurality of sleeves is positioned vertically with respect toits adjacent sleeve in the third plurality of sleeves to form a thirdstack of sleeves, positioning a fourth plurality of computers into afourth plurality of sleeves, wherein each sleeve in the fourth pluralityof sleeves is sized to slidingly accommodate at least one computer ofthe fourth plurality of computers wherein each sleeve in the fourthplurality of sleeves is positioned vertically with respect to itsadjacent sleeve in the fourth plurality of sleeves to form a fourthstack of sleeve, positioning the first stack of sleeves adjacent to thesecond stack of sleeves to form a first row of stacks having a frontside and a back side, positioning the third stack of sleeves adjacent tothe fourth stack of sleeves to form a second row of stacks having afront side and a back side, positioning the first row of stacks adjacentto the second row of stacks such that the back side of the first row ofstacks and the back side of the second row of stacks face each other andform an unobstructed vertical air flow path, creating an outlet aircurrent from an inside space of each computer to an exterior spaceproximate to each computer through a plurality of outlet air flow holesdefined within a front wall of each computer housing, creating a firstinlet air current from the vertical air flow path to the inside space ofeach computer through a plurality of holes defined on a top wall of eachcomputer such that the plurality of holes are exposed beyond a rear ofthe respective sleeve of the first, second, third, and fourth pluralityof sleeves, and creating a second inlet air flow from the exterior spaceproximate to each computer to the inside space of each computer througha plurality of inlet air flow holes defined on a side wall of eachcomputer.